Chemical Process Industries Ch.E-203

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1 Chemical Process Industries Ch.E-203 Umair Aslam Assistant Professor Department of Chemical Engineering

2 Process Movement of data or material towards a known goal or end result, by passing it through a series of stages or a sequence of actions. Depratment of Chemical Engineering 2

3 Sections Of A Chemical Plant Process Utility Safety Maintenance Ware House Research and Development Quality and Control Laboratories Administration Depratment of Chemical Engineering 3

4 Course Outline Introduction to process flow sheeting, process flow diagrams, standard symbols Detailed study of the following group of industries: Water treatment Acid industries Hydrochloric acid Sulphuric acid Nitric acid Phosphoric acid Depratment of Chemical Engineering 4

5 Alkali industries Soda Ash Caustic Soda Ammonia Fertilizer (NPK based fertilizers) Cement industry Explosives Sugar industry Pulp and Paper industry Oil and Ghee industry Glass and Ceramics industry Soap and Detergent Insecticides and Surface coating industries Petro-chemicals Depratment of Chemical Engineering 5

6 Books Shreve s Chemical Process Industries,5 th Or 6 th Edition, George T. Austin Introduction To Chemical Processes (Principles, Analysis And Synthesis), International Edition, Regina M. Murphy A Text Book Of Chemical Technology, G. N. Pandey, Volume I Chemical Engineering, D. Kuznetsov Hawley's Condensed Chemical Dictionary Depratment of Chemical Engineering 6

7 State States of matter Steady state Uniform state Phase Temperature Pressure Heat Flow Equipment/Apparatus/Instruments Depratment of Chemical Engineering 7

8 Reaction Physical Chemical Separation/Purification Heat Exchange Depratment of Chemical Engineering 8

9 Chemical Process Diagrams The most effective way of communicating information about a process is through the use of flow diagrams. Flow Diagrams Block Flow Diagrams (BFD) Process Flow Diagrams (PFD) Piping and Instrument Diagrams (P&ID) often referred to as Mechanical Flow Diagram Complexity increases Conceptual understanding increases As chemical engineers, we are most familiar with BFD and PFD.

10 The Block Flow Diagram (BFD) BFD shows overall processing picture of a chemical complex Flow of raw materials and products may be included on a BFD BFD is a superficial view of facility

11 The Block Flow Diagram (BFD) Emphasis is not on details regarding blocks; focus on flow of streams through process. Conventions: Operations shown by blocks Major flow lines shown with arrows giving flow direction Flow goes from left to right whenever possible Light streams toward top, heavy streams toward bottom Critical information unique to the process supplied (i.e., reaction stoichiometry, conversion) Avoid crossing lines; horizontal continuous, vertical broken. Simplified material balance (overall)

12 The Block Flow Diagram (BFD)

13 The Block Flow Plant Diagram

14 The Process Flow Diagram (PFD) PFD shows all process engineering information Typical conventions (vary by company): All major equipment represented, uniquely numbered All process flow streams shown and uniquely numbered, with description of thermodynamic conditions and composition (often in an accompanying table) All utility streams supplied to major process equipment shown Basic control loops, illustrating control strategy during normal operation

15 Process Flow Diagram (cont d)

16 Process Flow Diagram (cont d)

17 The Process Flow Diagram (cont d) Essential Information Stream Number Temperature ( C) Pressure (bar) Vapor Fraction Total Mass Flow Rate (kg/h) Total Mole Flow Rate (kmol/h) Individual Component Flow Rates (kmol/h) Optional Information Component Mole Fractions Component Mass Fractions Individual Component Flow Rates (kg/h) Volumetric Flow Rates (m 3 /h) Significant Physical Properties Density Viscosity Other Thermodynamic Data Heat Capacity Stream Enthalpy K-values Stream Name

18 Piping & Instrument Diagram Piping & Instrument Diagram (P&ID) Construction Bible Contains: plant construction information (piping, process, instrumentation) support documents of the PFD used for planning for plant construction and maintaining the plant thereafter Each PFD requires many P&IDs to provide the necessary data Used as a checklist at the final walk-through prior to start up to assure each detail has been attended to Use by/to MEs and CEs to build/install equipment Instrument engineers to specify/install/check control systems Piping engineers to develop plant layout and elevation drawings Project engineers to develop plant and construction schedules

19 Piping & Instrument Diagram

20 Stream Numbering & Drawing Number streams left to right when possible Horizontal lines are dominant yes no no

21 Stream Information - Flags

22 Stream Drawing

23 Depratment of Chemical Engineering 23

24 Depratment of Chemical Engineering 24

25 Depratment of Chemical Engineering 25

26 Depratment of Chemical Engineering 26

27 Depratment of Chemical Engineering 27

28 Depratment of Chemical Engineering 28

29 Depratment of Chemical Engineering 29

30 Depratment of Chemical Engineering 30

31 Depratment of Chemical Engineering 31

32 Depratment of Chemical Engineering 32

33 Depratment of Chemical Engineering 33

34 Depratment of Chemical Engineering 34

35 Depratment of Chemical Engineering 35

36 Depratment of Chemical Engineering 36

37 Depratment of Chemical Engineering 37

38 Depratment of Chemical Engineering 38

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